Poultry processing method and apparatus

ABSTRACT

Method and apparatus for scalding fowls in a sanitary manner so that scald water utilized in the scalding of the body of one fowl is not reused in the scalding of the bodies of other fowls.

United States Patent Sharp 154] POULTRY PROCESSING METHOD AND APPARATUS[72] Inventor: Allen W. Sharp, 1540 North Van Buren Street, Ottumwa,Iowa 52501 [22] Filed: Dec. 28, 1970 211 Appl. No.: 101,907

[52] U.S.Cl ..l7/47,17/1l.1 [51] int. Cl ..A22c 21/02 [58] FieldofSearch ..l7/11.2, 11.1, 15,51,47,

[56] References Cited UNITED STATES PATENTS Oehring 17/51 51 Nov. 21,1972 1,848,596 3/1932 Allbright ..17/l5' 3,074,103 1/1933 Rothetal...17/47 3,343,477 9/1967 Ekstam..v ..17/15 X Primary ExaminerLucie H.Laudenslager Attorney-Molinare, Allegretti, Newitt & Witcoff [571ABSTRACT Method and apparatus for scalding fowls in a sanitary manner sothat scald water utilized in the scalding of the body of one fowl is notreused in the scalding of the bodies of other fowls.

6 Claims, 5 Drawing Figures POULTRY PROCESSING METHOD AND APPARATUSBACKGROUND OF THE INVENTION This invention relates to a novel method andapparatus for processing fowls, after killing, preparatory to performingeviscerating operations upon the fowls.

Commercial processors of fowls now utilize mechanical equipment forcontinuously moving the fowls through the steps of killing, scalding,picking and eviscerating operations. The commonly used method andapparatus for scalding fowls consists of total immersion of the bodiesof the fowls in tanks of hot water, maintained at desirable temperatureranges, depending on the character and nature of the fowls beingprocessed, for the purposes of conditioning the skin of the bodies ofthe fowls, and for facilitating removal of the feathers from the bodiesof the fowls. Scalding by the immersion process has long been condemnedby Government inspection services because of the contamination of thefowls by the filth and bacteria of fowls previously immersed in thescald tank. In addition to the contamination of fowls by filth andbacteria present in the scald water from previously processed fowls, itsometimes happens that when the fowls move into the scald tank, if theyhave not completely stopped breathing, there is the likelihood that thecontaminated scald water may be drawn up into the lungs or other part ofthe circulatory system of the fowl and render the same unfit forconsumption.

Such immersion scald operations are permitted to continue to be used,notwithstanding the unsanitary conditions, solely because of the lack ofavailability of suitable methods and apparatus by virtue of which fowlsmay be scalded in a sanitary manner. There have been numerous attemptsheretofore made to provide methods and apparatus for the scalding offowls in a sanitary manner for commercial processing. For example, theBarker, et al. US. Pat. No. 2,813,298, dated Nov. 19, 1957, is directedto a method of processing fowl by batches, that is relatively smallnumbers at a time, which efiects a substantial reduction in extent ofcontamination of fowls by filth and bacteria on the bodies of otherfowls. The Amstad US. Pat. No.. 3,138,822, dated June 30, I964, isdirected to a method and apparatus by virtue of which fowls may besubjected to a scald operation while they are individually suspended onan overhead conveyor and by virtue of which the scalding operation wouldappear to be capable of accomplishment in a sanitary manner. In theprocess and apparatus disclosed in this latter patent the fowls, afterkilling, pass through a chamber, while i being moved by an overheadconveyor, where they are subjected to high velocity sprays of hot waterand also to circulated heated air containing moisture.

The present invention is directed to a method and apparatus which isrelatively simple and inexpensive and by virtue of which the fowls,while individually suspended from an overhead conveyor, may be scaldedin a novel, sanitary manner.

One of the objects of this invention is to provide a novel method andapparatus for processing fowls in a manner to insure sanitary andefficient scalding operations to be performed upon the bodies of thefowls on a mass production basis, and which insures substantiallyelimination of all contamination of the body of a fowl by precedingfowls processed by an automated processing system.

Another object of this invention is to provide a novel method andapparatus for processing fowls wherein the fowls, after killing, arefirst subjected to a preliminary picking operation for the removal ofthe major portion of the feathers from the bodies of the fowls, afterwhich the bodies of the fowls are subjected to a scalding action, andthen to a final picking action to effect the removal of the remainingfeathers from the bodies of the fowls.

.A further object is to provide a novel method and apparatus forprocessing fowls which permits the performance of an efficient,controlled, sanitary scald operation upon the bodies of the fowls bysubjecting the fowls, while being individually suspended on an overheadconveyor, to a fluid mixture of steam and water, and wherein thequantity of water is in excess of that necessary to maintain theadmixture at substantially percent humidity, whereby portions of saidexcess water are caused to be deposited directly upon the bodies of thefowls for performing a scalding operation thereon.

Still another object is to provide a novel method and apparatus of thecharacter indicated, which effects a substantial reduction in the amountof heat necessary for performing the scald operation upon the fowls andthus effecting substantial economies to the processor.

A still further object of this invention is to provide a novel methodand apparatus of the character indicated, which permits utilization ofthe novel scald apparatus in conjunction with existing, conventionalpicking machines, which results in substantial savings to existingprocessors desiring to utilize the novel scalding method and apparatusof the present invention.

It is also an object of this invention to provide a novel method andapparatus of the character indicated, which effects a substantialreduction in the amount of floor space necessary for the performing ofscalding and picking operations upon the fowls.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatic view, in sideelevation, of the apparatus embodying the present invention;

FIG. 2 is an end elevational view of the scalding apparatus, takensubstantially as indicated at line 22 on FIG. 1;

FIG. 3 is an enlarged transverse sectional view through the scaldingapparatus, taken substantially as indicated at line 3-3 on FIG. 1;

FIG. 4 is an enlarged sectional view of the humidifier for creating anatomized admixture of water and steam, taken substantially as indicatedat line 4-4 on FIG. 3;

FIG. 5 is a top view of the humidifier shown in FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENT The method and the apparatusembodying the present invention are utilized in connection with aconventional, overhead conveyor 10, from which fowls indicated at 12 aresuspended by their feet in a customary manner. The fowls, after killingand bleeding, are moved along the overhead conveyor into a machineindicated at 14, for performing a preliminary picking operation upon thebodies of the fowls, preferably by the use of unheated water. Thepicking machine may be of any of the conventionally used types. Duringthis preliminary picking operation, the majority of the feathers on thebodies of the fowls are totally removed and when the fowls move out ofthe preliminary picking machine, their bodies are substantially bald.The fowls then move immediately into the novel scalding apparatusindicated generally at 16. As shown, the scalding apparatus is made upof three interconnected units, 16a, 16b and 16c, each including acabinet or casing 18, formed to provide a continuous chamber 20 throughall of the units. The casings enclose a portion of the overheadconveyor, and the suspended fowls 12 are continuously moved through thechamber 20 of the scalding apparatus.

Each unit of the scalder apparatus, depending upon its length, isprovided with its own centrifical blower 22 for discharging fluid in anupwardly direction through the duct portion 24 into the chamber 20 ofcasings of the units to circulate the fluid around and over the bodiesof the fowls suspended on the overhead conveyor. The fluid in the systemis continuously recirculated and for this purpose I provide a returnduct 26 to continuously withdraw fluid from the lower portion of thechamber 20, into the centrifical blower. interposed in the upwardly openduct 24 of each unit is a humidifier spray assembly, which includes anupwardly open cup-shaped body 30, in the bottom wall of which is mountedan atomizer nozzle 32, connected to pipe 33 a source of water supply.The nozzle 32 is preferably designed for the creation of an atomizedspray of water in cone-shaped formation, and of a cross-sectionaldimension to preclude impingement upon the side wall of the upwardlyopen cup-shaped body. Opening to the interior of the cup-shaped body isa steam supply conduit 36, which discharges steam tangentially to theinner wall of the cup-shaped body and by virtue of which the steamsurrounds and admixes with the spray of water, and heats the water tothe desired temperature. It is to be understood that the fluid admixtureshall be such as to completely saturate the air and provide an excessquantity of water for entrainment in the air. This excess water, overand above the 100 percent humidity of the air, is entrained in the fluidby the stream eminating from the blower 22 at a velocity suffrcient tocause the fluid admixture to rapidly circulate through the chamber 20,into contact with the bodies of the fowls moving therethrough, whichresults in depositing portions of said excess water of the admixturedirectly upon the bodies of the fowls (which at this time have the majorportion of their feathers removed) for quickly and efficientlyperforming a conditioning and scalding operation upon the bodies of thefowls.

Suitable controls are preferably associated with each unit of thescalding section, such as a thermometer 40 extending into the upperportion of the chamber 20, and a temperature controller device 42, ofconventional type, for automatic controlling of the valves supplyingsteam and water to the humidifier so as to obtain and maintain precisetemperature and humidity and excess moisture conditions within thecasing 20.

As is well-known, the temperatures at which fowls are scalded varysubstantially, depending upon the size,

age and character of the fowls being processed. For example, in scaldingchickens the temperature of the scald liquid is preferably in the rangeof 126 14 134F. As to the number of units or sections, or the length ofthe scalding apparatus to be utilized, will depend upon the speed oftravel of the overhead conveyor, as well as upon the size and characterof the fowls being processed. For example, in scalding of turkeys orchickens of one year of age or more, the scalding temperature would bepreferably in the range of 138 -140 F., and the scald operation may, ifdesired, be of longer duration than for fryers or broilers.

The fluid utilized in the scalding process and apparatus preferablyshould be accurately controlled and maintained at percent humidity plusan excess quantity of moisture, which excess will serve to precludeevaporation, and make it possible to maintain closely controlled,accurate temperatures within the scalding chamber. It might be said thatthe excess of water in the fluid admixture of steam and water, over andabove 100 percent humidity, is in the nature of a light rain or mist inthat it will be present in relatively fine atomized form for depositupon the fowls, and which will effect an efficient scalding operationupon the bodies of the fowls.

The scalding casing unit 160, at the inlet end, is formed with anextension 16d, providing an extension of chamber 20 and having agenerally rectangular entrance opening l6e, as seen in FIG. 2, toaccommodate the overhead conveyor and the passage of the suspended fowlbodies into the scalding chamber. At the outer end of the last unit 16cof the scalder apparatus through which the fowls pass, there is anextension 16f corresponding oppositely and identically to the extension16d at the inlet end, and having an exit opening similar to opening 16e,through which the fowls move out of the scalder apparatus.

In each of the extensions 16d and 16f, at the inlet and outlet endsrespectively, there is provided a suitable duct 46, opening at one endto the interior of said extensions, and the opposite end being connectedinto the casing of the adjacent respective blower 22. By virtue of thisarrangement, fluid within the scalding chamber is continuously withdrawnimmediately adjacent the respective inlet and outlet openings, andrecirculated throughout the chamber of the scald apparatus. Thisarrangement in effect provides the equivalent of an air curtain,constituting a substantial closure for the inlet and outlet openings,and reducing to a minimum the introduction of outside air into thecirculating fluid system of the scalding apparatus. If desired, therespective inlet and outlet openings of the scalding chamber may beprovided with flexible flaps of any suitable material, which will serveto provide a degree of closing off of the inlet and outlet openings,while permitting the passage of the bodies of the fowls therethrough.

After the fowls have been scalded they are moved by the overheadconveyor into one or more conventional picking machines 50, for theremoval of the balance of the feathers from the bodies of the fowls,thereby completing the removal of all feathers from the fowls,preparatory to performing eviscerating operations thereon.

While I have illustrated in the diagrammatic view of FIG. 1, separatespaced apart cabinet or casing structures for performing the picking andscalding operations, if desired, the cabinet structures could beinterconnected so that the fowls are caused to move through atunnel-like enclosure throughout the picking and scalding operations,and in which case the side walls of the cabinets or casings would beprovided with suitable doors for ready access to and examination of thefowls during processing, or for cleaning, adjusting and repairing theapparatus. I prefer that the cabinet units, namely picking and scaldingapparatus, be separated short distances so that the condition of thepicking and scalding operations being performed upon the fowls can bereadily observed, and so that access for cleaning, adjustment and repairof the separate apparatus may be conveniently attended to or made.

It will be apparent that performing a preliminary picking operation uponthe fowls, prior to scalding, is of substantial importance because bythe removal of the major portion of the feathers from the bodies of thefowls, prior to scalding, the scalding operation when performed can bemore accurately and efficiently controlled and performed. In performingthe scalding method by the use of fluid of 100 percent humidity, and ofa desired temperature, together with an excess amount of water entrainedtherein in the form of a light rain or mist, which is blown against andcollects upon the bodies of the fowls, an efficient, sanitary scaldingoperation is attained. The excess moisture over and above 100 percenthumidity, carried in the circulating fluid within the chamber, isprimarily to control the temperature of the excess moisture bypreventing evaporation, which makes it possible to obtain relativelyfine or accurate and constant temperature control within one-fourth of adegree. Such control is highly important for efficiency, and because thetemperature of the scald is critical.

By the use of moisture in excess of 100 percent humidity in thecirculating fluid medium, there must be enough water in the fluid mediumto give up its heat and quickly drain off from the bodies of the fowl.The amount of water and steam utilized in the fluid medium would besubstantially less than that used in conventional scalders, which arecurrently in extensive use today, wherein Government inspection servicesrequire the addition of k gallon of hot water as make-up and overflowwater per fowl. Hence, my novel method and apparatus will result insubstantial savings, both in the quantity of water and the amount ofheat required in performing of the scalding operation.

While the novel method and apparatus for performing the scald operationwill perform an effective and efficient scalding action, if desiredadditional spray nozzles may be utilized for projecting sprays of scaldwater, of desired temperature, directly upon the bodies of the fowls.

It will be recognized that with the novel method and apparatus forscalding, it requires a matter of a few minutes to place the system intooperation as compared the speed of the conveyor being in the range of 50to feet per minute. Since the fowls will be substantially bald whenentering the scalder, the time for performin the scaldin o erationshould not take than fr m 30 to 40 s coiids to complete. To accomgfigfiscalding in this short period of time would require a scalder of a shortlength of 25' to 65 feet, depending upon the speed of travel of the,overhead conveyor moving the bodies of the fowls through the scalder,and the nature of the fowls to be processed.

It is believed that finish picking of the fowls will probably beaccomplished in a shorter period of time due to having the main portionof the feathers removed from the bodies of the fowls during preliminarypicking prior to scalding, and further due to the performance of a moreuniform scald upon the bodies of the fowls by the novel scald method andapparatus.

What is claimed is:

l. The method of processing fowls, after killing, preparatory toperforming eviscerating operations thereon, comprising the step ofsubjecting the fowls to a preliminary picking operation for removing themajor portions of the feathers from the bodies of the fowls, after saidpreliminary picking the step of subjecting the fowls to a scaldingoperation for loosening the remainder of the feathers on the bodies ofthe fowls and the step of subjecting the fowls to a final pickingoperation for removal of the remainder of the feathers from the bodiesof the fowls.

2. The method defined in claim 1, wherein the step of scalding ischaracterized as including the subjection of the bodies of the fowls toan admixture of steam and water with the quantity of water beingsufficient to provide substantially 100 percent humidity of theadmixture.

3. The method defined in claim 1, wherein the step of scalding ischaracterized as including the subjection of the bodies of the fowls toan admixture of steam and water wherein the quantity of water in theadmixture is in excess of that necessary to maintain the admixture atsubstantially 100 percent humidity.

4. The method defined in claim 3, wherein the admixture is caused tomove into direct contact with the bodies of the fowls for depositingthereon a portion of said excess quantity of water.

5. The method defined in claim 1, wherein the step of preliminarypicking of the fowls is performed with the use of unheated water.

6. The method defined in claim 1, wherein each of the steps aresequentially performed while the fowls are being supported, and movedalong on overhead conveyors.

Disclaimer 3,703,021.AZZ@n W. Sharp, Ottumwa, Iowa. POULTRY PROCESSINGMETHOD AND APPARATUS. Patent dated Nov. 21, 1972. Disclaimer filed Feb.12, 1975, by the inventor. Hereby enters this disclaimer to claims 1, 2,3, 4 and 6 of said patent.

[Oyficial Gazette May 20, 1975.]

1. The method of processing fowls, after killing, preparatory toperforming eviscerating operations thereon, comprising the step ofsubjecting the fowls to a preliminary picking operation for removing themajor portions of the feathers from the bodies of the fowls, after saidpreliminary picking the step of subjecting the fowls to a scaldingoperation for loosening the remainder of the feathers on the bodies ofthe fowls and the step of subjecting the fowls to a final pickingoperation for removal of the remainder of the feathers from the bodiesof the fowls.
 1. The method of processing fowls, after killing,preparatory to performing eviscerating operations thereon, comprisingthe step of subjecting the fowls to a preliminary picking operation forremoving the major portions of the feathers from the bodies of thefowls, after said preliminary picking the step of subjecting the fowlsto a scalding operation for loosening the remainder of the feathers onthe bodies of the fowls and the step of subjecting the fowls to a finalpicking operation for removal of the remainder of the feathers from thebodies of the fowls.
 2. The method defined in claim 1, wherein the stepof scalding is characterized as including the subjection of the bodiesof the fowls to an admixture of steam and water with the quantity ofwater being sufficient to provide substantially 100 percent humidity ofthe admixture.
 3. The method defined in claim 1, wherein the step ofscalding is characterized as including the subjection of the bodies ofthe fowls to an admixture of steam and water wherein the quantity ofwater in the admixture is in excess of that necessary to maintain theadmixture at substantially 100 percent humidity.
 4. The method definedin claim 3, wherein the admixture is caused to move into direct contactwith the bodies of the fowls for depositing thereon a portion of saidexcess quantity of water.
 5. The method defined in claim 1, wherein thestep of preliminary picking of the fowls is performed with the use ofunheated water.